Apparatus and method for forimng fascia molding

ABSTRACT

An apparatus (10) includes internal mechanisms (18, 20, 24) for advancing, guiding and roll forming fascia molding (30, 30a) from sheet material (14) fed from coil stock (16) or in precut sheets (72). The fascia molding (30, 30a) includes a roll formed curved profile (32) in between angled top and bottom portions.

TECHNICAL FIELD

The present invention relates generally to roll forming, and moreparticularly to a new and unique method and apparatus for forming fasciamolding in continuous lengths.

BACKGROUND OF THE INVENTION

Various types of trim pieces are used in the construction industry tocomplete the exteriors of buildings. For example, fascia is typicallyused underneath the eaves and at the gable ends of houses. Fasciagenerally serves two purposes. Primarily, it serves to cover and closethe intersection between the upper end of the wall and the outside endof the adjacent roof edge. However, such fascia also serves to provide aneat and finished appearance to the building, which is also important.

In the past, such fascia has typically been made from pieces of solidmaterial, such as wood, shaped to the desired cross-sectional profile,cut to length and then separately fastened to the building. These ofcourse are exposed to the weather and elements, requiring maintenance,the frequency of which depends upon the location of the building. Suchmaintenance is time consuming, difficult and expensive.

Various building products such as siding and roofing, have beenavailable heretofore for reducing building maintenance. However, therehas not been available a fascia molding formed from substantiallymaintenance-free materials which can be manufactured in continuouslengths.

Similarly, various machines have been available heretofore formanufacturing gutters, siding, soffit panels and the like. However,there has not been available an apparatus for roll forming fasciamolding in continuous lengths from substantially maintenance-freematerial.

A need has thus arisen for an apparatus and method for forming fasciamolding in continuous lengths from substantially maintenance-freematerial in order to reduce the costs associated with the fascia of theprior art.

SUMMARY OF THE INVENTION

The present invention comprises an apparatus and method for-formingfascia molding which overcomes the foregoing and other difficultiesassociated with the prior art. In accordance with the invention, theleading end of a strip of suitable material from a roll or coil is fedinto one end of an enclosure or housing, which includes a drivemechanism for advancing it along a predetermined feed path. Apredetermined arrangement of various guides and rollers define the feedpath. As the material advances along the feed path, it is progressivelyformed by the guides and rollers into a unique fascia molding incontinuous lengths, which can be cut to the desired length by a shear orcutting mechanism as it exits the other end of the enclosure. The fasciamolding can then be applied to a building, thus avoiding thedifficulties and unnecessary costs associated with the prior art.

BRIEF DESCRIPTION OF DRAWING

A better understanding of the invention can be had by reference to thefollowing Detailed Description in conjunction with the accompanyingDrawing, wherein:

FIG. 1 is a perspective view of an apparatus for forming fascia moldingin continuous lengths in accordance with the present invention;

FIGS. 2-9 are schematic profiles illustrating the various steps informing the fascia molding herein;

FIG. 10 is a schematic profile of a modification to the fascia moldingherein; and

FIGS. 11 and 12 are schematic illustrations showing two typicalinstallations of the fascia molding herein.

FIG. 13 is a perspective view of a modified apparatus for forming fasciamolding in preselected lengths in accordance with the present invention;

FIG. 14 is a plan view of a section of material with holes preformedalong its opposite edges before forming; and

FIG. 15 is a plan view of a section of material precut across itsopposite ends in order to facilitate forming a mitre joint.

DETAILED DESCRIPTION

Referring now to the Drawing, wherein like reference numerals designatelike or corresponding elements throughout the views, and particularlyreferring to FIG. 1, there is shown an apparatus for forming fasciamolding 10. The apparatus 10 includes an elongate housing or enclosure12 having opposite front and back ends. Apparatus 10 can be supported onlegs 13 as shown, in a fixed position, or carried on a mobile platform(not shown) such as a trailer or within a truck for transportationto/from a work site.

Strip material 14 from a roll or coil of stock 16 is fed into the frontend of the enclosure 12. The flat strip material 14 can comprise sheetmetal, such as aluminum, which may be coated on one side 14 a anduncoated on the other side 14 b. Material 14 comprises bendable ormalleable sheet material like that used in forming gutters and the like.In the preferred embodiment, the material 14 comprises aluminum about 12to 15 inches wide and about 0.027 or 0.029 inch thick, coated with paintor vinyl on side 14 a and uncoated in mill finish on the opposite side14 b. Any suitable material or coatings can be used.

The coil of stock 16 can be supported on a stand (not shown) in front ofthe enclosure 12, or mounted on top of the enclosure. In the preferredembodiment, the stock coil 16 is supported so that the material 14 isfed into the enclosure 12 with the coated side 14 a facing up, as shown.

Within the enclosure 12 of the apparatus 10 are a motor and drivemechanism 18 and a guide and roller arrangement 20 defining a feed pathfor advancing the material 14 through the machine. A shear or blademechanism 22 is located at the front end of enclosure 12 for cutting thefascia molding 30 to length as it comes out. The shear mechanism 22 ismanually actuated by handle 24.

The drive mechanism 18, guide and roller arrangement 20 and cuttermechanism 22 of apparatus 10 are constructed and arranged in a new andunique combination from elements similar to those found in prior guttermachines. For example, see U.S. Pat. Nos. 3,529,461, 4,899,566,5,551,272 and 6,931,903 to Knudson, the entire disclosures of which arehereby incorporated by reference herein.

FIGS. 2-9 illustrate the various steps in forming the flat material 14into the fascia molding 30. The first step involves roll forming alongitudinal curved shape or profile 32 inward from one longitudinaledge 33. Reference numerals 33 and 36 designate the opposite side edgesof profile 32. In the preferred embodiment as shown, the profile 32 isan oggee shape, although a crown profile, cove profile or other suitableprofile of any desired shape can be used.

After the profile 32 has been formed, material 14 is then folded or bentin one direction upwardly along a longitudinal fold line 34 at one sideof profile 32, as best shown in FIG. 3. The portion of material 14 thusfolded or bent upwardly includes profile 32 and the flat portionadjacent to edge 33 between the profile and edge 33.

After the portion of material 14 inward from edge 33 has been folded inone direction upwardly, the material is bent downwardly in the otherdirection along longitudinal fold line 38 about 90 degrees to form anupper attachment flange 40 along the upper edge 33 of the fascia molding30.

The portion of material 14 along the opposite edge 42 is also bentupwardly in one direction about 90 degrees along fold line 44 and thenbent back downwardly in the other direction about 90 degrees along foldline 46, as best seen in FIGS. 4 and 5.

The flat and profile portions of material 14 inward from the edge 33 arethen bent downwardly about 90 degrees along longitudinal fold line 48and then bent back upwardly about 90 degrees along longitudinal foldline 50 to form the flat side of the fascia molding 30, as best seen inFIGS. 6 and 7.

The distance between fold lines 46 and 50, defining the flat side of thefascia molding 30, can vary depending upon the particular buildingapplication.

Meanwhile, the portion of material 14 along the opposite edge 42 is bentinwardly about 90 degrees along longitudinal fold line 52 and then bentback downwardly about 90 degrees along longitudinal fold line 54 to forma lower attachment flange 56 of the fascia molding 30, as best seen inFIG. 9.

FIG. 11 shows a typical installation the fascia molding 30. In thepreferred embodiment, the lower attachment flange 56 is secured byfasteners 58 to wall sheathing 60, behind the upper edge of siding 62.The upper attachment flange 40 is secured by fasteners 64 to the outeredge of the roof sheathing 66.

FIG. 10 shows a modified fascia molding 30 a, similar to fascia molding30, except that the lower attachment flange 56 has been cut off alongfold line 54, in order to provide support for soffit 68 under the roofeave, as shown in FIG. 12.

Although a particular sequence of steps have been shown and describedherein for manufacturing the fascia molding 30, another sequence ofsteps in a different order could be used. Also, some steps could becombined and/or carried out simultaneously instead of sequentially, ifdesired.

If desired, longitudinally spaced-apart, holes or perforations (notshown) could be provided in the flanges 40 and 56 for receivingfasteners 64 and 58, respectively. Such holes or perforations would beelongated to allow for thermal expansion and contraction. Also, edges 33and 42 could be folded back upon themselves for additional rigidity andreinforcement of flanges 40 and 56, respectively.

FIG. 13 shows an apparatus for forming fascia molding 70 incorporating asecond embodiment of the invention herein. Since apparatus 70incorporates components substantially similar to apparatus 10, the samereference numerals have been used, but with prime (′) notations fordifferentiation.

Instead of forming fascia molding 30 in continuous fashion from coil 16,which is then cut to length as desired with shear 24, apparatus 70utilizes precut sheets 72 of material 14′ to form sections of fasciamolding in precut lengths. Otherwise, the manufacturing steps are thesame. In the preferred embodiment, the sheets. 72 of material 14′ areprecut in any suitable length, such as 10, 12, or 16 feet long.

If desired, longitudinally spaced-apart, precut holes or perforations 74can be provided along the opposite edges of each sheet 72 before formingthe flanges 40 and 56 in fascia molding 30, as shown in FIG. 14.

Similarly, as FIG. 15 shows, one of both of the ends of each sheet 72can be precut in a predetermined profile to facilitate joining twosections of fascia molding 30 together. For example, the ends of sheet72 can be precut to facilitate making a mitre joint with and between twosections of fascia molding 30 during installation.

From the foregoing, it will be appreciated that the present inventioncomprises an apparatus and method for forming fascia molding havingseveral advantages over the prior art. One significant advantage is theease of installation when the fascia molding can be made in continuousfashion and cut to length according to the particular buildingapplication, thus avoiding the seams and piecemeal approachcharacterized by the prior art. This results in efficiencies and costsavings in manufacturing, installation and maintenance. Other advantageswill be evident to those skilled in the art.

Although particular embodiments of the invention have been illustratedin the accompanying Drawing and described in the foregoing DetailedDescription, it will be understood that the invention is not limitedonly to the embodiments disclosed, but is intended to embrace anyequivalents, modifications and/or rearrangements of elements fallingwithin the scope of the invention as defined by the following Claims.

What is claimed is:
 1. A method of manufacturing fascia molding,comprising the steps of: a. providing a sheet of malleable material,said sheet having opposite longitudinal side edges, and oppositesurfaces; b. advancing said sheet along a predetermined feed path; c.roll forming a predetermined longitudinal profile into said sheet, saidprofile being spaced inwardly between the side edges thereof; d. rollforming a longitudinal first portion of said sheet between said profileand one adjacent side edge in one transverse direction; e. roll formingsaid first portion and said profile in the opposite transversedirection; and f. roll forming a second portion of said, sheet betweensaid profile and the other side edge sequentially in both transversedirections to form inner and outer sections, the outer section adjacentsaid other side edge being substantially parallel to said first portionand spaced a predetermined distance away from the second portion by theinner section.
 2. The method of claim 1, wherein the malleable materialis aluminum in coil form.
 3. The method of claim 1, wherein themalleable material is aluminum in precut flat sheet form.
 4. The methodof claim 1, wherein the longitudinal profile is an oggee.
 5. The methodof claim 1, wherein the angle between the inner and outer sections ofsaid second portion is about a right angle.
 6. The method of claim 1,wherein the angle between the inner and outer sections of said secondportion is about a right angle.
 7. The method of according to claim 6,wherein the angle between the inner section and said second portion isabout a right angle.
 8. The method of claim 1, further including thestep of: g. roll forming a third portion of said sheet between saidprofile and the said other side edge sequentially in both transversedirections to form inner and outer middle sections, the inner middlesection being adjacent to said profile.
 9. The method according to claim8, wherein the angle between the inner and outer middle sections of saidthird portion is about a right angle.
 10. The fascia moldingmanufactured according to the method of claim
 1. 11. A method ofmanufacturing fascia molding, comprising the steps of: a. providing aflat sheet of malleable material, said sheet having oppositelongitudinal side edges, and opposite surfaces; b. advancing said sheetalong a predetermined feed path; c. roll forming a predeterminedlongitudinal profile into said sheet, said profile being spaced inwardlybetween the side edges thereof; d. roll forming a longitudinal firstportion of said sheet between said profile and one adjacent side edge inone transverse direction; e. roll forming said first portion and saidprofile in the opposite transverse direction; f. roll forming a secondportion of said sheet between said profile and the other side edgesequentially in both transverse directions to form inner and outersections, the outer section adjacent said other side edge beingsubstantially parallel to said first portion and spaced a predetermineddistance away from the second portion by the inner, section, and g. rollforming a third portion of said sheet between said profile and the saidother side edge sequentially in both transverse directions to form innerand outer middle sections, the inner middle section being adjacent tosaid profile.
 12. The method of claim 11, wherein the malleable materialis aluminum in coil form.
 13. The method of claim 11, wherein themalleable material is aluminum in precut flat sheet form.
 14. The methodof claim 11, wherein the longitudinal profile is an oggee.
 15. Themethod according to claim 14, wherein the oggee is offset relativelycloser to said one side edge.
 16. The method of claim 11, wherein theangle between the inner and outer sections of said second portion isabout a right angle.
 17. The method of claim 11, wherein the anglebetween the inner and outer sections of said middle portion is about aright angle.
 18. The fascia molding manufactured according to the methodof claim
 11. 19. Apparatus for manufacturing fascia molding frommalleable sheet material, which comprises: an elongate, generallyrectangular enclosure having front and back ends; means for feeding thesheet material into the front end of said enclosure; means for advancingsaid material along a predeterminded feed path within said enclosure;means positioned along the feed path for progressively roll forming saidmaterial into fascia molding by the steps of: a. roll forming apredetermined longitudinal profile into said sheet, said profile beingspaced inwardly between the side edges thereof; b. roll forming alongitudinal first portion of said sheet between said profile and oneadjacent side edge in one transverse direction; c. roll forming saidfirst portion and said profile in the opposite transverse direction; d.roll forming a second portion of said sheet between said profile and theother side edge sequentially in both transverse directions to form innerand outer sections, the outer section adjacent said other side edgebeing substantially parallel to said first portion and spaced apredetermined distance away from the second portion by the innersection, and e. roll forming a third portion of said sheet between saidprofile and the said other side edge sequentially in both transversedirections to form inner and outer middle sections, the inner middlesection being adjacent to said profile.
 20. The apparatus of claim 19,further including: means associated with the back end of said enclosurefor selectively cutting said fascia molding to length.